Oil level sensor guide

ABSTRACT

A fluid tank system comprises a fluid container that includes a sensor opening in a fluid container wall defined by a rim, and a fluid level sensor comprising a radial flange on a proximate end of a longitudinally extending electronics stem that includes a distal end. The distal end of the electronic stem is inserted into the fluid container via the sensor opening and the radial flange seats on the rim. The distal end of the electronics stem is guided via a first radial support and a second radial support to a seat that is located coaxial with the sensor opening, where the first and second radial supports are longitudinally separated and radially spaced apart to allow the electronics stem to longitudinally pass between the first and second radial supports until the flange seats on the rim ensuring that the distal end of the electronic stem is longitudinally positioned adjacent to the seat.

This application is a divisional of U.S. patent application Ser. No.15/620,311 filed Jun. 12, 2017, which is hereby incorporated byreference in its entirety.

BACKGROUND OF THE INVENTION 1. Technical Field

The present disclosure relates generally to fluid containers with asensor therein to measure fluid level. More particularly, the disclosurerelates to an oil tank with a sensor therein to measure oil level in thetank, for use in a gas turbine engine.

2. Background Information

During operation of a gas turbine engine oil is used to lubricate andcool rotating gears. Assembly of an oil level sensor into an oil tanklocated on a gas turbine engine can be a challenge when the oil levelsensor is assembled in an inverted orientation (e.g., during replacementof the sensor on engine and the sensor is inserted generally verticallyupward into the tank). Proper installation is required to preventassembly damage to surrounding parts and the sensor itself. In addition,it is essential that the oil level sensor is installed correctly becausesealing surfaces on the oil tank must adhere to tight tolerances toavoid leaks.

It would be desirable to reduce the chance of oil level sensormisassembly and reduce oil sensor removal and replacement time.

SUMMARY OF THE DISCLOSURE

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of the disclosure. The summary is not anextensive overview of the disclosure. It is neither intended to identifykey or critical elements of the disclosure nor to delineate the scope ofthe disclosure. The following summary merely presents some concepts ofthe disclosure in a simplified form as a prelude to the descriptionbelow.

Aspects of the disclosure are directed to a fluid tank system. The fluidtank system comprises a fluid container that includes a sensor openingin a fluid container wall defined by a rim. The fluid tank system mayalso comprise a fluid level sensor comprising a radial flange on aproximate end of a longitudinally extending electronics stem thatincludes a distal end. The fluid tank system may further comprise alongitudinally extending assembly tooling element that this insertedinto an assembly tool bore of the fluid container wall, where, as thelongitudinally extending electronics stem passes through the sensoropening the assembly tooling element passes through a guide aperture inthe radial flange ensuring that the distal end of the electronics stemis co-axially aligned and positioned with respect to the seat.

The fluid level sensor may comprise a float that co-axially surroundsthe electronics stem.

The fluid level sensor may comprise a magnetic reed switch sensor wherethe float comprises a permanent magnet.

According to another aspect of the present disclosure, a fluid tankassembly is provided. The fluid tank assembly may include a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim. The fluid tank assembly may further comprise a fluidlevel sensor comprising a radial flange on a proximate end of alongitudinally extending electronics stem that includes a distal end.The distal end of the electronics stem may be inserted into the fluidcontainer via the sensor opening and the radial flange seats on the rimthat forms the sensor opening, and the distal end of the electronicsstem is guided to a seat that is located coaxial with the sensor openingvia a support that extends longitudinally inward to the fluid containerfrom the fluid container wall, where the electronics stem slides alongthe support until the radial flange seats on the rim ensuring that thedistal end of the electronic stem is longitudinally positioned adjacentto the seat.

The support includes a first face surface that is concave and alongwhich the stem slides during insertion into the fluid container.

The fluid level sensor may comprise a float that co-axially surroundsthe electronics stem.

According to another aspect of the present disclosure, a fluid tankassembly is provided. The fluid tank assembly may comprise a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim. The fluid tank assembly may further comprise a fluidlevel sensor comprising a radial flange on a proximate end of alongitudinally extending electronics stem that includes a distal end.The distal end of the electronic stem may be inserted into the fluidcontainer via the sensor opening and the radial flange seats on the rim,and the distal end of the electronics stem is guided via a first radialsupport and a second radial support to a seat that is located coaxialwith the sensor opening, where the first and second radial supports arelongitudinally separated and radially spaced apart to allow theelectronics stem to longitudinally pass between the first and secondradial supports until the flange seats on the rim ensuring that thedistal end of the electronic stem is longitudinally positioned adjacentto the seat.

The first radial support and the second radial support may be unitarywith the fluid container wall.

The first radial support and the second radial support may be fastenedto an interior side of the fluid container wall.

According to another aspect of the present disclosure, a fluid tankassembly is provided. The fluid tank assembly may comprise a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim. The fluid tank assembly may further comprise a fluidlevel sensor comprising a radial flange on a proximate end of alongitudinally extending electronics stem that includes a distal end.The distal end of the electronics stem may be inserted into the fluidcontainer via the sensor opening that includes complex curved interiorside walls extending inward to an interior of the fluid container, wherethe complex curved shape of the interior side walls allows theelectronics stem to axially pass through the sensor opening to radiallyposition the distal end of such that when the radial flange seats on therim the distal end axially and radially positioned in the seat.

According to another aspect of the present disclosure, a fluid tankassembly is provided. The fluid tank assembly may comprise a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim. The fluid tank assembly may also comprise a fluidlevel sensor comprising a radial flange on a proximate end of alongitudinally extending electronics stem that includes a distal end.The distal end of the electronics stem may be inserted into the fluidcontainer via the sensor opening and as the distal end of the electronicstem reaches a first axial position and passes deeper into the fluidcontainer an O-ring housing radially surrounding and attached to theelectronics stem pushes radially outward a spring assembly that radiallysurrounds the electronics stem and the O-ring housing, and as the O-ringhousing continues deeper into the fluid container and reaches a secondaxial position the spring assembly moves radially inward applying aradial aligning force to the electronics stem such that when the flangeseats on the rim the distal end of electronics stem is axially andradial positioned in the seat.

The spring assembly partially radially surrounds the electronics stemand the O-ring housing.

The spring assembly continuously radially surrounds the electronics stemand the O-ring housing.

The spring assembly may comprise a first plurality of springs eachlongitudinally separated in an axial direction.

The spring assembly may comprise a second plurality of springs eachlongitudinally separated in an axial direction, where the first andsecond plurality of springs are radially opposing with respect to thelongitudinally extending electronics stem.

The fluid level sensor may comprise a float that co-axially surroundsthe electronics stem.

The fluid level sensor may comprise a magnetic reed switch sensor wherethe float comprises a permanent magnet.

According to another aspect of the present disclosure, a fluid tankassembly is provided. The fluid tank assembly may comprise a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim. The fluid tank assembly may further comprise a fluidlevel sensor comprising a radial flange on a proximate end of alongitudinally extending electronics stem that includes a distal end.The fluid tank assembly may also comprise a guide tube that radiallysurrounds the electronics stem and axially contacts a flanged surface ofthe longitudinally extending electronics stem located within the fluidsurface, where the longitudinally extending electronics stem, the guidetube and the sensor opening are co-axial about a central axis.

The guide tube may free float about the longitudinally extendingelectronics stem.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example and not limitedin the accompanying figures in which like reference numerals indicatesimilar elements. The drawing figures are not necessarily drawn to scaleunless specifically indicated otherwise.

FIG. 1 is a side cutaway illustration of a geared turbine engine.

FIG. 2 is a simplified illustration of the interior of a split case oiltank that includes an oil level sensor.

FIG. 3 is a simplified illustration of the interior of a split case oiltank that includes an oil level sensor and assembly tooling guide pinsused for assembly of the sensor in the tank.

FIG. 4A is a simplified illustration of a portion of the interior of asplit case oil tank that includes a guide partially surrounding a sensoropening in the oil tank case.

FIG. 4B illustrates the interior of the split case oil tank of FIG. 4Awith the sensor operatively positioned within the tank.

FIG. 5A is a simplified illustration of a portion of the interior of asplit case oil tank that includes an alternative embodiment guidepartially surrounding a sensor opening in the oil tank case.

FIG. 5B illustrates the interior of the split case oil tank of FIG. 5Awith the sensor operatively positioned within the tank.

FIG. 6 is a simplified illustration of the interior of a split case oiltank that includes a first radial support and a second radial support,where the first and second radial supports are axially and radiallyspaced apart to allow an electronic stem of the oil level sensor toaxially pass between the first and second radial supports ensuring thatthe distal end of the electronic stem is longitudinally positionedadjacent to the distal end seat.

FIGS. 7A-7C are cross sectional illustrations of a portion of the lengthof a sensor opening in a fluid tank sidewall that includes complexcurved interior side walls and a distal end on the sensor progressivelymoving through the length of the sensor opening.

FIG. 8 is a pictorial illustration of the portion of the length of thesensor opening illustrated in FIGS. 7A-7C, including a flange that seatson an exterior surface of the fluid tank.

FIGS. 9A-9D are cross sectional illustrations of a portion of the lengthof a sensor opening in a fluid tank sidewall that includes an O-ringhousing surrounding the electronic stem progressively pushing open aspring assembly, which radially surrounds the electronic stem as thedistal end of the electronic stem continues deeper into the fluidcontainer until it reaches a second position, and the spring assemblycloses applying a radial aligning force to the electronic stem such thatwhen the flange seats on the rim the distal end of electronic stem isaxially and radially positioned in the seat.

FIG. 10 is a perspective view of a first case of a split case fluidtank.

FIG. 11 is a cross sectional illustration of a portion of the split casefluid tank of FIG. 11 illustrating an integral oil sensor guide.

DETAILED DESCRIPTION

It is noted that various connections are set forth between elements inthe following description and in the drawings (the contents of which areincorporated in this specification by way of reference). It is notedthat these connections are general and, unless specified otherwise, maybe direct or indirect and that this specification is not intended to belimiting in this respect. A coupling between two or more entities mayrefer to a direct connection or an indirect connection. An indirectconnection may incorporate one or more intervening entities or aspace/gap between the entities that are being coupled to one another.

Aspects of the disclosure may be applied in connection with a gasturbine engine. FIG. 1 is a side cutaway illustration of a gearedturbine engine 10. This turbine engine 10 extends along an axialcenterline 12 between an upstream airflow inlet 14 and a downstreamairflow exhaust 16. The turbine engine 10 includes a fan section 18, acompressor section 19, a combustor section 20 and a turbine section 21.The compressor section 19 includes a low pressure compressor (LPC)section 19A and a high pressure compressor (HPC) section 19B. Theturbine section 21 includes a high pressure turbine (HPT) section 21Aand a low pressure turbine (LPT) section 21B.

The engine sections 18-21 are arranged sequentially along the centerline12 within an engine housing 22. Each of the engine sections 18-19B, 21Aand 21B includes a respective rotor 24-28. Each of these rotors 24-28includes a plurality of rotor blades arranged circumferentially aroundand connected to one or more respective rotor disks. The rotor blades,for example, may be formed integral with or mechanically fastened,welded, brazed, adhered and/or otherwise attached to the respectiverotor disk(s).

The fan rotor 24 is connected to a gear train 30, for example, through afan shaft 32. The gear train 30 and the LPC rotor 25 are connected toand driven by the LPT rotor 28 through a low speed shaft 33. The HPCrotor 26 is connected to and driven by the HPT rotor 27 through a highspeed shaft 34. The shafts 32-34 are rotatably supported by a pluralityof bearings 36; e.g., rolling element and/or thrust bearings. Each ofthese bearings 36 is connected to the engine housing 22 by at least onestationary structure such as, for example, an annular support strut.

As one skilled in the art would appreciate, in some embodiments a fandrive gear system (FDGS), which may be incorporated as part of the geartrain 30, may be used to separate the rotation of the fan rotor 24 fromthe rotation of the rotor 25 of the low pressure compressor section 19Aand the rotor 28 of the low pressure turbine section 21B. For example,such an FDGS may allow the fan rotor 24 to rotate at a different (e.g.,slower) speed relative to the rotors 25 and 28.

During operation, air enters the turbine engine 10 through the airflowinlet 14, and is directed through the fan section 18 and into a core gaspath 38 and a bypass gas path 40. The air within the core gas path 38may be referred to as “core air”. The air within the bypass gas path 40may be referred to as “bypass air”. The core air is directed through theengine sections 19-21, and exits the turbine engine 10 through theairflow exhaust 16 to provide forward engine thrust. Within thecombustor section 20, fuel is injected into a combustion chamber 42 andmixed with compressed core air. This fuel-core air mixture is ignited topower the turbine engine 10. The bypass air is directed through thebypass gas path 40 and out of the turbine engine 10 through a bypassnozzle 44 to provide additional forward engine thrust. This additionalforward engine thrust may account for a majority (e.g., more than 70percent) of total engine thrust. Alternatively, at least some of thebypass air may be directed out of the turbine engine 10 through a thrustreverser to provide reverse engine thrust.

FIG. 1 represents one possible configuration for an engine 10. Aspectsof the disclosure may be applied in connection with other environments,including additional configurations for gas turbine engines.

FIG. 2 is a simplified illustration of the interior of a split casefluid tank 200 (e.g., a gas turbine engine mounted oil tank) thatincludes a fluid level sensor 202. The split case tank include a firstcase 204 and a complementary second case (not shown) that when securedtogether form a fluid vessel. The tank 200 includes a sensor opening 206formed in a first wall 208 of the first case 204. To sense the level offluid in the tank, the tank includes the sensor 202 that provides asignal indicative of level of fluid in the tank. The sensor 202 mayinclude an electronic stem 210 that longitudinally extends into the tankvia the sensor opening 206 in the first wall 208. The fluid sensor 202comprises a radial flange 212 located adjacent to a proximate end 214 ofthe longitudinally extending electronic stem, which also includes adistal end 216. The sensor also includes a guide tube 218 that radiallysurrounds the stem.

When the distal end 216 of the electronic stem is inserted into the tankvia the sensor opening 206, the guide tube 218 radially aligns thedistal end 216 with a distal end receiver 220. The longitudinal lengthof the guide tube 218 is selected based upon the length of the tank thatthe distal end 216 has to traverse. For example, the longer the distanceto traverse the longer the guide 218 should be to ensure the distal end216 is in radial alignment with the distal end receiver 220 when theflange 212 seats on a rim of the sensor opening 206.

FIG. 3 is a simplified illustration of the interior of a split case oiltank 240 that includes an oil sensor 242 and assembly tooling guide pins244, 246 used for placement and assembly of the sensor 242 in the tank.In this embodiment, distal end 248 of sensor electronic stem 250 isinserted into the fluid tank via sensor opening 252 in a tank wall andflange 254 seats on a rim 256 of the tank that forms the sensor opening252. In this embodiment the distal end of the electronics stem is guidedto a seat 256 located coaxial to the sensor opening 252.

During assembly of the sensor into the tank, the assembly tooling guidepins 244, 246 are inserted into assembly tool bores 258, 260 in the rim.As the longitudinally extending electronic stem 250 passes through thesensor opening 252 the assembly tooling guide pins 244, 246 pass throughapertures 261, 262, respectively, of the flange 254, ensuring that thedistal end 248 of the electronic stem is aligned and positioned withrespect to the seat 256. Once the flange 254 is seated on the rim (e.g.,via a gasket), then the assembly tooling guide pins 244, 246 are moved,and fasteners (not shown) are inserted into the assembly tool bores 258,260 to secure the flange 254 to the rim 256.

In another embodiment for operably positioning the sensor in the tank,FIG. 4A is a simplified illustration of a portion of the interior of asplit case fluid tank 270 that includes a guide 272 partiallysurrounding a sensor opening 274 in tank case 276. The guide 272 may besecured to the tank case 276 and extends longitudinally inward asufficient distance to guide sensor stem 278 in order to align sensordistal end 280 with distal end receiver (not shown in FIG. 4A). Theguide 272 may also be a unitary component of the tank case 276. Thelength of the guide 272 is dependent on the length of the tank (e.g.,distance between sensor opening 274 and distal end receiver).

FIG. 4B illustrates the interior of the split oil tank 270 of FIG. 4Awith the sensor stem 278 operatively positioned within the tank, with aflange 282 of the sensor secured to a rim of the tank (e.g., with agasket between).

FIG. 5A is a simplified illustration of a portion of the interior of thesplit case oil tank of FIGS. 4A and 4B. The embodiment in FIG. 5A issubstantially the same as the embodiments in FIGS. 4A and 4B with theprincipal exception that guide 290 has a substantially concave surface292 radially facing the sensor stem 278, such that as the stem isinserted into the tank the guide 290 aligns the distal end of the stemwith the distal end receiver inside the tank. The guide 290 may apply aslight spring force radially against the sensor stem 278 to position thestem during assembly.

FIG. 5B illustrates the interior of the split case oil tank of FIG. 5Awith the sensor operatively positioned within the tank.

FIG. 6 is a simplified illustration of the interior of a split casefluid tank 294 that includes a first radial support 300 and a secondradial support 302, where the first and second radial supports 300, 302are axially (i.e., longitudinally) separated and radially spaced apartto allow sensor stem 304 to axially pass between the first and secondradial supports. The supports 300, 302 cooperate to ensure distal end306 of the electronic stem is longitudinally positioned adjacent to adistal end seat 308.

In yet another embodiment, FIGS. 7A-7C are a series of cross sectionalillustrations of a portion of the length of a sensor opening 310 in afluid tank sidewall. The sensor opening 310 comprises complex curvedinterior sidewalls 312, 314. As a distal end 316 of a fluid level sensorprogressively moves through the length of the sensor opening 310, thecomplex curved interior sidewalls 312, 314 cooperate to properly alignthe distal end 316.

FIG. 8 is a pictorial illustration of the portion of the length of asensor opening illustrated in FIGS. 7A-7C, including a flange 318.

FIGS. 9A-9D are a series of cross sectional illustrations of a portionof the length of a sensor opening in a fluid tank sidewall 340 thatincludes a spring holder 342 positioned co-axially along a central axis343 with respect to a sensor opening 344 in the fluid tank sidewall 340.The spring holder 342 extends axially inward from the tank sidewall 340and includes a plurality of springs 348-353 (e.g., coiled springs). Theinterior opening formed by the spring holder 342 may be co-axial withthe sensor opening 344 about the axis 343. A first set 348-350 of theplurality of springs may be spaced apart axially, and on an oppositeradial side of the spring holder 342 a second set 351-353 of theplurality of springs may also be spaced apart axially. The first set348-350 and the second set 351-353 of the plurality of springs may beradially opposing with respect to the axis 343.

The spring holder 342 may include a radially interior surface 356 thateach of the springs applies a radial force to. In the interest of easeof illustration the radial exterior surface that the springs contact isnot shown. Referring to FIG. 9A, as distal end 357 of the sensor stempasses axially further into the fluid tank through the sensor opening344, an O-ring projection 358 of the level sensor electronic stemcontacts a tapered distal end surface 360 of the spring holder 342. Asthe distal end 357 and the O-ring projection 358 move axially inward theO-ring projection 358 displaces the radially interior surface 356radially outward against spring forces. The radially opposing springsapply forces to the radial interior surface 356 that align the distalend 357 of the fluid level sensor with a stem receiver (not shown)located at a distal end of the fluid tank. The axial and radialarrangement of the plurality of springs 348-353 and the resultant forcesapplied by the radial interior surface 356 against the sensor stemproperly aligns the distal end 357 with the cooperating stem receiverlocated at a distal end of the fluid tank coaxial with the sensoropening.

Referring now to FIG. 9B, as the O-ring projection 358 moves furtheraxially inward the radial interior surface 356 is radially displaced. InFIG. 9C the O-ring projection 358 is even further axially inward incomparison to FIG. 9B, and the projection 358 displaces a distal end ofthe surface 356. In FIG. 9D, the O-ring projection 358 has passedaxially inward beyond a distal end 359 of the surface 356 allowing thesurface 356 to contact and align the stem. That is, as shown in FIG. 9Dthe radially interior surface 356 applies opposing radial force againstthe sensor stem to align the distal end 357 with the stem receiver.

It is contemplated that the radially interior surface 356 may be asingle surface that surrounds an area co-axial with the sensor opening344, or the radially interior surface 356 may comprise a plurality ofsurfaces that surrounds the area co-axial with the sensor opening 344.In either embodiment the interior surface(s) align the distal end 357 ofthe sensor stem to ensure proper installation on the level sensor. Atapered distal end 360 of the O-ring projection 358 may be used to allowthe O-ring projection 358 to smoothly engage the spring holder 342.

To assist with removal of the sensor from the tank, the spring holder342 includes a tapered proximate end surface 368, which is smoothlycontacted by the tapered surface 370 of the O-ring projection as thefluid level sensor is being removed from the tank.

FIG. 10 is a perspective view of a first case 380 of a split case fluidtank. The first case 380 may be a unitary component that is cast,machined or additively manufactured. The first case 380 includes a fluidlevel sensor opening 382.

FIG. 11 is a cross sectional illustration of a portion of the first case380 of FIG. 10 illustrating an integral oil sensor guide 384 thatincludes a plurality of fluid leak holes 386-388 that allow fluid toenter the sensor guide and contact the sensor therein in order to sensethe fluid level. In this embodiment the guide 384 radially surrounds thesensor stem that would be inserted via the sensor opening 382

While various embodiments of the present invention have been disclosed,it will be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of theinvention. For example, the present invention as described hereinincludes several aspects and embodiments that include particularfeatures. Although these features may be described individually, it iswithin the scope of the present invention that some or all of thesefeatures may be combined with any one of the aspects and remain withinthe scope of the invention. Accordingly, the present invention is not tobe restricted except in light of the attached claims and theirequivalents.

What is claimed is:
 1. A fluid tank system, comprising: a fluidcontainer that includes a sensor opening in a fluid container walldefined by a rim; a fluid level sensor comprising a radial flange on aproximate end of a longitudinally extending electronics stem thatincludes a distal end; a guide tube that radially surrounds thelongitudinally extending electronics stem and axially contacts a flangedsurface of the longitudinally extending electronics stem located withinthe fluid container, where the longitudinally extending electronicsstem, the guide tube and the sensor opening are co-axial about a centralaxis, the guide tube comprising an inner radial surface which defines asensor cavity and an outer radial surface, the outer radial surface andthe fluid container defining a fluid cavity therebetween, the guide tubefurther comprising at least one fluid leak hole extending through theguide tube from the outer radial surface to the inner radial surface;wherein the fluid container comprises a first end having the sensoropening and a second end opposite the first end and wherein the guidetube extends from the sensor opening to the second end of the fluidcontainer and contacts the second end of the fluid container; andwherein a proximate end portion of the sensor cavity located at thesensor opening has a first diameter and a distal end portion of thesensor cavity opposite the proximate end portion has a second diameterand wherein the first diameter is greater than the second diameter. 2.The fluid tank system of claim 1, wherein the at least one fluid leakhole is located in the guide tube proximate the distal end portion ofthe sensor cavity.
 3. The fluid tank system of claim 1, wherein theguide tube is integrally formed with the fluid container.